Building construction



Dec. 12, 1944. w NEFF 2,365,145

BUILDING CONSTRUCTION 2 Sheets-Sheet 1 Filed April 3, 1941 f, I x

Dec. 12, 1944. NEFF 2,365,145

BUILDING CONSTRUCTION Filed April 3, 1941 2 Sheets-Sheet 2 3a 35 33" 3a v 6 Patented Dec. 12, 1944 UNITED STATES PATENT OFFICE 17 Claims.

This invention relates to improvements in building construction and, with regard to its more specific aspects, to thin-shell concrete buildings particularly adapted for defense and low cost housing projects, and to the method of constructing the same.

Among the objects of the present invention maybe noted the provision of a building designed for use as a dwelling, barracks and the like which satisfies defense standards requiring not only that it provide adequate shelter, but also that it be small, that it can be scattered with relation to other buildings of a group thereof, and that it be fireproof; the provision of a building of the stated character which can be fabricated at minimum cost and in quantity, thus satisfying the requirements of low cost housing; the provision of a thin-shell concrete structure of the continuous wall or span type which is so constructed as to eliminate the requirement for joists, beams, studding, girders, and like structural parts, and which nevertheless possesses sufflcient strength as to withstand all normal stresses to which it may be subjected; the provision of thin-shell concrete structures of barrel; vault or dome shape constituted by a. continuous wall or span in which all stresses are predominantly those of compression, with the shell being substantially self-sustalning and requiring only minimum reinforcement for the negligible lateral stresses; the provision of a novel concrete construction particularly adapted for use as dwellings, barracks, small hangars, and the like; the provision of a concrete building of the character described which may be fabricated in situ, both inexpensively and in quantity; the provision of an improved method of building construction; and the provision of an improved and novel method of erecting thin-shell concrete structures suitable for use as dwellings, barracks and the like.

Other objects will be in part obvious and in part hereinafter pointed out in connection with the following analysis of trs invention wherein is illustrated an embodiment of the invention in detail.

In the drawings:

Figure 1 is illustrative of a basic shelter unit (dwelling) constructed in accordance with the invention.

Figure 2 is an end view thereof.

Figure 3 is illustrative of another form of dwelling unit in accordance with the invention.

Figures 4 and 5 are respectively schematic plan and elevational views illustrating the preferred mode of erecting the structure centering.

Figure 6 is a somewhat idealized vertical section through the shell and foundation of a completed structure.

Figure '7 is a detail partly in section of the preferred top securing means for the centering elements.

Figure 8 is a typical section along line l-B of Figure 1.

Figure 9 is a typical section along line 9-9 of Figure l, and

Figure 10 is a typical section taken along line lll lll of Figure 1.

Referring now to the drawings wherein like reference characters designate like parts throughout the several views, Figures 1 and 2 represent one form of a basic shelter unit in accordance with the invention. The unit shown is essentially constituted by a relatively elongated concrete shell of arch or vault section, to be hereinafter referred to as a barrel shell, the single wall thereof being in the nature of a continuous span providing an arched roof portion In integral with the curved sides ll, l2. While the interior of the structure is not shown, it will be understood that due to the continuous span construction and the fact that the span or wall is under compression throughout with no tendency of the side walls to spread due to lateral stresses, all interior roof ties and span-sustaining structural elements are eliminated. Thus in a building as aforesaid the entire cubical capacity of the arch interior may be utilized.

The unit illustrated is of length, width and height as to provide the necessary space for a dwelling to include a living-room, dining-room, kitchen, and bath, the interior partitions being preferably of plaster on metal lath construction. To support the metal lath of the partitions, suitable means, not shown, may be lmbedded in or otherwise formed in the shell structure during its construction. In the event it is desired to provide overhead storage space within the interior, such as over the kitchen, the partition or partitions supporting such storage space may be of conventional stud construction.

The end walls l3, ll, like the interior partitions may be of plaster on metal lath construction. However, where an end wall assists in supporting the storage space, the wall or the supporting portion thereof may be of conventional stud construction.

Suitable openings in the shell are provided for windows IS, a main entrance door It and a service door ll, if the latter is desired, the manner of providing the same to be described in the following description.

While the unit under description has been referred to as a dwelling of size such as to provide shelter for a small family, the unit may be enlarged by the addition of other units of like construction, to provide a dwelling for a larger family. Thus, addition units may be coupled to one or both ends of the basic unit illustrated or may be built on the unit illustrated intermediate the ends thereof to provide a structure in the nature of a cross vault. Obviously, the construction illustrated has wider use in the field of defense housing than as a family dwelling, and is ideally suited for use as military or naval barracks, small-size hangars and like structures.

In Figure 3, there is illustrated another form of basic unit in accordance with the present invention, such being fabricated as a concrete shell dome of height and interior diameter as to provide, for example, space for a combined living and sleeping room, a combined kitchen and dinette, and a bath, as required by a small family. As in the case of the barrel shell dwelling, all interior partitions are preferably of plaster on metal lath, although if the partition is to support loads as in the case of an overhead storage space provided over one of the rooms, the same may be of conventional stud construction. Suitable openings for windows 2| anda door 22 are provided as will appear from the following descrip tion. Addition units may be connected to the basic unit shown by a passage way or corridor of barrel arch form, and the floor plan suitably arranged for a larger family.

Considering now the construction method of the present application, by which both the barrel shell and the shell dome structures described in the foregoing may be inexpensively fabricated in quantity, said shells are built up on a previously laid concrete slab 25 (Figure 6) which is substantially rectangular for the barrel shell structure and circular for the shell dome structure. The foundation slab, which may be placed within a channel form 26 of removable and sectional construction, preferably includes a marginal footing 21. The slab proper and its footing may be suitably reinforced in conventional manner, and is preferably laid over a gravel bed and suitably waterproofed. Dowels 28 or the equivalent, to which the framework or centering for the shell is secured as will hereinafter appear, may be set into the slab during laying 7 thereof, suitable markings provided on the form 26 being preferably employed for locating the dowels.

In fabricating both the barrel shell and shell dome structures, the same general steps of construction are followed and the hereinafter description of one method chosen for purpose of description of constructing shell domes can be regarded as exemplary of the methods followed with both forms of structure.

According to this preferred method, the concrete shell is formed on a permanent centering in the nature of an open or basket-like framework 29 lathed on the inside, which is suitably anchored to the foundation slab 25. As an aid in handling and erecting, this framework is formed from pref p segments or so u 29a (see Figures 4 and 5) n t up of vertical channels 30 shaped to proper curvature, to which are secured as by wiring or welding the horizontal channels 3| which for the shell domes barrel shell structures extend straightway. To the inside face of the vertical channels of a segment, expanded metal lathing 32 (see Figure 6) is secured as by wiring. The lower horizontal channels of the segments may have holes punched therein for bolts or like securing means functioning to secure the segments to the dowels 28 of the foundation slab. Similarly the upper ends of the vertical channels may be punched to provide holes for bolts securing said upper ends to a circular dolly 33 carrying a channeled securing ring 330 into which the ends of the channels are set. In the case of barrel shells, a longitudinal ridge channel or form is provided in place of the circular dolly.

A requisite number of prefabricated segments or sections 29a, each carrying its own interior lathing as described, is set up on the foundation slab 25, thus to provide a framework of desired shape and contour, the lower ends of the segmerit channels being bolted to the dowels 2i and the upper ends bolted or otherwise secured to the dolly 33 (or to the ridge channel). The dolly is preferably supported at the required level by a removable wooden post during assembly of the segments. Adjacent segments are secured together as by bolts although other forms of securement such as spot welding may be employed. Such an interiorly lathed framework provides a permanent centering for the concrete shell to be placed thereon in accordance with the fol lowing.

For insulating the final structure, it is preferred to lay a blanket 35 of known insulation material disposed between sheets of paper on the exterior of the framework (see Figures 6 and 10), the blanket being secured as by wiring to the vertical channels. Other insulating media may be employed, such as a sheet of waterproof felt paper.

Over the insulation is laid metal reinforcing mesh 36, the same being secured preferably by the tie wires which secure the insulating blanket to the vertical channels, and along its lower edge to the foundation slab dowels 23a.

An alternate mode of securing the insulation and outer reinforcing mesh to the framework is to provide the vertical (and/or horizontal) channels with integral, outstruck prongs which pierce the insulation and pass through the reinforcing mesh as the latter are laid, whereupon the prongs are bent flat to secure the blanket and mesh to the framework.

The exterior of the framework is then shot with concrete by a well known process according to which a mixture of cement, fine aggregate and water is placed by a portable pneumatic cement gun. The concrete is shot on to the centering to form a layer or shell 33 having a depth of about 2 (approximate). To embed the reinforcing mesh 36 which has a tendency to he against the insulating blanket 35, the meal. is held out to a proper distance from the insulation by a helper provided with a long hook who moves along with the gun operator as the shell is progressively shot. Other means such as furring strips for holding the reinforcing mesh out from the insulation can of course be employed.

Due to the shooting of the cement mixture under considerable pressure, the cement upon drying forms a densely compacted and homogeneous concrete shell admirably suited to sustain the stresses to which it is subjected, in which it is assisted by the centering. Moreover, the procare shaped to e d ed C a e. and for essing is such that the concrete of the outer shell is intimately bonded to the insulation and hence to the centering against which it is placed, with the resulting structure being in the nature of a continuous wall or span forming either the barrel shell or dome shell type of structure.

The manner of providing openings such as doors and windows for the final structure will now be described. Reference character I (Figure 8) designates one side iamb board of a unitary and complete opening frame of size to outline the door opening, a. side lamb board ll of a generally similar window frame being shown in Figure 9. The side lamb boards 40 and ll are roughly triangular to accommodate for the curvature of the wall and also to provide for the vertical disposition of the window or door set therein. In the case of the door frame, however, the side jamb boards I of the frame are long enough to extend to the floor level. The door and window frames as aforesaid are set in place immediately following the erection of the reinforcing framework which will be provided with the necessary openings, and are each secured in place between two adjacent vertical channels 30 of the framework which are suitably spaced to receive the same and preferably also between two horizontal channels II a. Thus, the insulating blanket 35, the reinforcing mesh 36 and the concrete may be applied around the already setin frames.

Each side lamb board of a frame carries a vertically extending flashing 42 (Figure the relatively outer edge thereof being hooked into the side face of the lamb board as at 43 and the relatively inner end of the flashin being offset laterally as at ll, with the offset being adapted to lay against the relatively outer face of the vertical channels 30 between which the lamb boards are placed. The insulation blanket 35 and the stucco mesh 36 are laid on the flashing offsets 44 and the concrete is shot against th flashing proper, thus to provide a seal preventing ingress of water or moisture to the Joint between the jamb board and the adjacent concrete wall.

The head boards 48 of the opening frames Figures 8 and 9) are of substantial width and depth. thus to extend well outwardly from the curved wall of the structure. Each head board carries a flashing cap sheet 41 which is hooked or bent over the relatively outer edge of the board as at Ill and extends inwardly over the entire surface of the board, terminating in an upwardly directly offset 49 which preferably lays against the upper horizontal channel 3la bounding the framework opening. In the case of a window frame, the sill 50 thereof extends between the side lamb boards and rests on the lower horizontal channel defining the frame opening. For the door frame, whose side lamb boards extend to the floor level. the door sill may be laid on the foundation slab.

Thus, by the above arrangements, the d( 1r and window frames may be placed in unitary manner in openings provided in the centerlig and the outer concrete shell can be built up around the frames. In addition to the inexpensive placement of the frames and the fact that frames so disposed provide for the vertical disposition of windows and doors in walls which curve relatively inwardly and the further advantage that doors and windows so arranged possess architectural attractiveness, the provision of head and lamb boards about the window further serve the imscattered for dispersal purposes.

Hence. the arrangement materially aids in the prevention of detection of the structure from th air during periods of darkness.

For outside finish, the shot concrete surface is rodded to true curvature and left rough, or a finish or wash coat of cement may be shot on to the outer surface of the formed and hardened shell. Where exterior color is desired, such may be incorporated into the cement mixture prior to placement of the same.

For interior flnish, a coat 52 of plaster is applied against the iathlng of the centering in conventional manner. For floor finish, the exposed floor surface of the foundation slab may be treated in desired manner, or may be covered with linoleum or with wood block flooring laid in mastic, as may be desired.

As indicated in Figure '1, the dolly 33 is preferably prefabricated to include a diametral reinforcing beam 33b (Figure 7). and with an interior metal lathlng piece 33c laid over the top thereof. The cement mixture is shot on to the dolly to embed the same, with the lathing functioning as a centering for the tip or apex portion of the structure. The inner side of the dolly is faced with plaster, generally as shown.

Upon analysis of the foregoing. it will be seen that structures fabricated in accordance with the invention are essentially constituted by a substantially integral concrete shell providing a curved span extending from spaced anchoring points on the foundation slab, the span being so arranged and disposed as to eliminate the requirement for interior span supporting structural elements.

By reason of inexpensive construction and the fact that dwellings and shelters as illustrated can be fabricated in quantity, building construction as aforesaid is ideally suited for use as dwellings for defense workers and their families about factories or projects directly or indirectly related to national defense. By reason of the relatively small overall size of structures fabricated in accordance with the invention. such may be well In addition to its flreproofness, a structure in accordance with the invention is waterand vermin-proof, features of importance in the tropics, and further has indefinite life. Although a structure as contemplated could not be expected to stand up under a direct bomb hit, nevertheless such structures are splinter-proof and provide a high degree of protection against rifle and machine gun bullets.

As many changes could be made in carrying out the above constructions without departure from the scope of the invention, it is intended that all matter contained in the above descripportant function of cutting ofl upwardly directed light rays from lights within the structure.

tion or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

I claim:

1. A thin-shell concrete structure comprising a foundation. a shell-form permanent centering comprising a plurality of prefabricated sections assembled together on and secured to said foundation, and a shot-concrete continuous outer shell placed against said centering for support thereby during setting, said outer shell being substantially self-sustaining upon setting.

2. A thin-shell concrete structure comprising a foundation, a shell-form permanent centering mounted thereon. said centering being constituted by a plurality of prefabricated sections providing upon assembly an open reinforcing framework, a substantially continuous backing material carried by said framework, and a shotconcrete continuous outer shell placed against said centering for support thereby during setting, said outer shell being substantially self-sustaining upon setting.

3. A thin-shell concrete structure comprising a foundation, 5, shell-form permanent centering mounted thereon, said centering being constituted by an open reinforcing framework carrying substantially continuous backing material on its inner side, a layer of insulation disposed on the outer side of the framework, and a shot-concrete continuous outer shell placed against said centering and insulation for support by said centering during setting, said outer shell being substantially self-sustaining upon setting.

4. A thin-shell concrete structure comprising a foundation, a shell-form permanent centering mounted thereon, said centering being constituted by an open framework carrying a continuous backing material on its inner side, a layer of insulation disposed on the outer side of said framework, a covering of reinforcing mesh disposed over the insulation. and a shot-concrete continuous outer shell placed against said centering and insulation and embedding said mesh for support by said centering during setting, said outer shell being substantially self-sustaining upon setting.

5. A thin-shell concrete structure comprising a foundation, a shell-form permanent centering mounted thereon, said centering being constituted by prefabricated sections, each formed by spaced, vertically disposed and inwardly curved structural elements and each section carrying lathing forming with the lathing of adjacent sections a substantially continuous backing, means securing adjacent sections to the foundation and to each other, and a shot-concrete continuous outer shell disposed over and lying against said centering.

6. A thin-shell concrete structure comprising a foundation, 3, shell-form permanent centering mounted thereon, said centering being constituted by prefabricated sections, each formed by spaced, vertically disposed and inwardly curved structural elements and each section carrying lathing on its inner side, means securing adjacent sections to the foundation and to each other, a layer of insulating material carried by said centering on its outer side and a shot-concrete continuous outer shell disposed over said centering and lying against the insulation.

7. A thin-shell concrete structure comprising a foundation, a shell-form permanent centerin mounted thereon, said centering being constituted by prefabricated sections, each formed by spaced, vertically disposed and inwardly curved structural elements and each section carrying lathing on its inner side, means securing adjacent sections to the foundation and to each other, a layer of insulating material carried by said centering on its outer side, a reinforcing mesh disposed over said insulation, means securing the insulation and the mesh to the vertical structural elements, and a shot-concrete continuous outer shell on the centering, said shellembedding the reinforcing mesh and bonding with said insulation material.

8. A thin-shell concrete structure comprising a foundation, a centering arranged on said foundaticn, an opening frame operatively secured relative to said centering in a position corresponding to the desired position for an opening through the flnal structure, the opening frame carrying weather-sealing means along the sides thereof, and a continuous and selfsustaining outer shell of concrete placed against said centering and about the frame and its securing means in such manner that the centering supports the shell during setting thereof and the shell upon setting permanently secures the weather-sealing means within the shell wall.

9. A thin-shell concrete structure comprising a foundation, a centering anchored to said foundation and provided with openings therein, an opening frame carrying flashing strips, said frame being secured as a unit to said center within an opening thereof, and a shot-concrete continuous outer shell on said centering, said shell extending about said opening frame and substantially embedding the flashing strips thereof, whereby the frame is permanently set in said outer shell.

10. A thin-shell concrete structure comprising a foundation, a centering anchored to said foundation and having openings therein, an opening frame carrying flashing strips, said frame being secured as a unit to said centering within an opening thereof, said flashing strips extending along the sides and top of the frame and each terminating in an offset lying in the plane of the outer side of the centering, and a shot-concrete continuous outer shell on said centering, said shell extending about said opening frame and substantially embedding the flashing strips thereof, whereby the frame is permanently set into the outer shell.

11. The method of constructing concrete barrel and dome shells which consists in the steps of assembling on a suitable foundation a plurality of prefabricated centering sections adapted upon assembly to provide a permanent shellform centering, applying a layer of insulation to the outer side of the centering, and shooting a cement mixture on to the centering and against the applied insulation to a depth such that the mixture on hardening forms a continuous and substanatially self-sustaining concrete shell.

12. The method of constructing concrete barrel and dome shells which consists in the steps of erecting a permanent shell-form centering on a suitable foundation, applying a layer of insulation to the outer side of the centering, securing a reinforcing mesh over the insulation, and shooting a cement mixture on to the centering and against the applied insulation and mesh to a depth substantially in excess of that required to embed the mesh.

13. The method of constructing concrete barrel and dome shells which consists in the steps of erecting a permanent shell-form centering on a suitable foundation, said centering including interior lathing, applying a layer of insulation to the outer side of the centering, securing a reinforcing mesh over the insulation, shooting a cement mixture on to the centering and against the applied insulation and mesh to a depth substantially in excess of that required to embed the mesh and plastering on the interior lathing.

14. The method of constructing concrete barrel and dome shells which consists in the steps of prefabricating a plurality of like centering sections carrying interior lathing and which upon assembly form a permanent shell-form centering, assembling said sections on a foundation, applying insulation to the outer side of the centering, shooting a cement mixture on to the outer side of the centering and against the applied insulation to a depth such that the mixture on hardening forms a continuous and substantially self-sustaining shell, and plastering on the interior lathlng.

15. The method of constructing concrete barre] and dome shells which consists in the steps of prefabricating a plurality of like centering sections carrying interior lathing and which upon assembly form a permanent shell-form centering, assembling said sections on a foundation. applying insulation to the outer side of the centering, securing reinforcing mesh over the insulation, shooting a cement mixture on to the centering and against the applied insulation and mesh to a depth substantially in excess of that required to embed the insulation, and plastering on the interior lathing.

16. The method of constructing concrete barrel and dome shells which consists in the steps of erecting a shell-form centering on a suitable foundation, securing a complete opening i'rame unit in desired location against said centering, and shooting a cement mixture on to the centering and about said frame unit which upon hardening forms a continuous and substantially selfsustaining concrete shell having a door or window opening.

17. The method of constructing concrete barrel and dome shells which consists in the steps of erecting a shell-form centering on a suitable foundation, securing a complete opening frame unit carrying its own flashing in desired location against said centering, and shooting on to the centering and about the opening frame a cement mixture to a depth substantially embedding the frame flashing thereby to form a continuous concrete shell having a door ,or window opening.

WALLACE NEFF. 

